US6527825B1 - Process for preparing nanosize metal oxide powders - Google Patents

Process for preparing nanosize metal oxide powders Download PDF

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US6527825B1
US6527825B1 US09/762,128 US76212801A US6527825B1 US 6527825 B1 US6527825 B1 US 6527825B1 US 76212801 A US76212801 A US 76212801A US 6527825 B1 US6527825 B1 US 6527825B1
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copolymer
metal
percent
ethylene oxide
metal salt
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Henri J. M. Gruenbauer
Jacobus A. F. Broos
Ronald van Voorst
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Dow Global Technologies LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82B—NANOSTRUCTURES FORMED BY MANIPULATION OF INDIVIDUAL ATOMS, MOLECULES, OR LIMITED COLLECTIONS OF ATOMS OR MOLECULES AS DISCRETE UNITS; MANUFACTURE OR TREATMENT THEREOF
    • B82B3/00—Manufacture or treatment of nanostructures by manipulation of individual atoms or molecules, or limited collections of atoms or molecules as discrete units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/10—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of rare earths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/20—Catalysts, in general, characterised by their form or physical properties characterised by their non-solid state
    • B01J35/23—Catalysts, in general, characterised by their form or physical properties characterised by their non-solid state in a colloidal state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
    • B01J37/0018—Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • B22F1/054—Nanosized particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/16—Making metallic powder or suspensions thereof using chemical processes
    • B22F9/30—Making metallic powder or suspensions thereof using chemical processes with decomposition of metal compounds, e.g. by pyrolysis
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B13/00—Oxygen; Ozone; Oxides or hydroxides in general
    • C01B13/14—Methods for preparing oxides or hydroxides in general
    • C01B13/18—Methods for preparing oxides or hydroxides in general by thermal decomposition of compounds, e.g. of salts or hydroxides
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F17/00—Compounds of rare earth metals
    • C01F17/20—Compounds containing only rare earth metals as the metal element
    • C01F17/206—Compounds containing only rare earth metals as the metal element oxide or hydroxide being the only anion
    • C01F17/212—Scandium oxides or hydroxides
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F17/00—Compounds of rare earth metals
    • C01F17/20—Compounds containing only rare earth metals as the metal element
    • C01F17/206—Compounds containing only rare earth metals as the metal element oxide or hydroxide being the only anion
    • C01F17/218—Yttrium oxides or hydroxides
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F17/00—Compounds of rare earth metals
    • C01F17/20—Compounds containing only rare earth metals as the metal element
    • C01F17/206—Compounds containing only rare earth metals as the metal element oxide or hydroxide being the only anion
    • C01F17/224—Oxides or hydroxides of lanthanides
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F17/00—Compounds of rare earth metals
    • C01F17/20—Compounds containing only rare earth metals as the metal element
    • C01F17/206—Compounds containing only rare earth metals as the metal element oxide or hydroxide being the only anion
    • C01F17/224—Oxides or hydroxides of lanthanides
    • C01F17/229—Lanthanum oxides or hydroxides
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F17/00—Compounds of rare earth metals
    • C01F17/20—Compounds containing only rare earth metals as the metal element
    • C01F17/206—Compounds containing only rare earth metals as the metal element oxide or hydroxide being the only anion
    • C01F17/224—Oxides or hydroxides of lanthanides
    • C01F17/235—Cerium oxides or hydroxides
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
    • C01F17/00—Compounds of rare earth metals
    • C01F17/20—Compounds containing only rare earth metals as the metal element
    • C01F17/206—Compounds containing only rare earth metals as the metal element oxide or hydroxide being the only anion
    • C01F17/241—Compounds containing only rare earth metals as the metal element oxide or hydroxide being the only anion containing two or more rare earth metals, e.g. NdPrO3 or LaNdPrO3
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G23/00—Compounds of titanium
    • C01G23/04—Oxides; Hydroxides
    • C01G23/047—Titanium dioxide
    • C01G23/053—Producing by wet processes, e.g. hydrolysing titanium salts
    • C01G23/0536—Producing by wet processes, e.g. hydrolysing titanium salts by hydrolysing chloride-containing salts
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G25/00—Compounds of zirconium
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G25/00—Compounds of zirconium
    • C01G25/02—Oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y40/00—Manufacture or treatment of nanostructures
    • C—CHEMISTRY; METALLURGY
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    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2004/00—Particle morphology
    • C01P2004/60—Particles characterised by their size
    • C01P2004/64—Nanometer sized, i.e. from 1-100 nanometer
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/12—Surface area

Definitions

  • This invention relates to a process for producing nanoscale metals or metal based powders.
  • this invention relates to a process for preparing nanoscale powders from a metal salt solution and an amphiphilic material.
  • Metal or metal oxide particles of nanoscale and submicron size are a valuable industrial commodity finding use in many applications, including the manufacture of industrial catalysts such as might be employed in the chemical industry, in the manufacture of ceramics, of electronic components, coatings, manufacture of catalysts, capacitors, mechanical-chemical polishing slurries, magnetic tapes and as fillers, for example, for plastics, paints or cosmetics.
  • nanoscale powders are generally expensive and difficult to prepare in large quantities, thus limiting their applications, for example, to high technology ceramics.
  • the present invention is a process for preparing nanoscale metal or metal-based powder by calcining at a temperature sufficient to drive off organics from a composition that comprises (a) a solution containing at least one metal salt (b) an amphiphilic ethylene oxide-containing copolymer wherein the copolymer has an average molecular weight of greater than 400, an ethylene oxide content of 1 to 90 percent and an hydrophilic-lipophilic balance (HLB) of between ⁇ 15 and 15 and (c) optionally a coagulating agent, with the proviso that when aluminum is the sole metal, a coagulating agent is present.
  • a composition that comprises (a) a solution containing at least one metal salt (b) an amphiphilic ethylene oxide-containing copolymer wherein the copolymer has an average molecular weight of greater than 400, an ethylene oxide content of 1 to 90 percent and an hydrophilic-lipophilic balance (HLB) of between ⁇ 15 and 15 and (c) optionally a coagulating agent,
  • the process produces metal-based powders of high purity and uniform size.
  • the paste formed in the present process by the mixing of the metal salt and copolymer contains a high concentration of metal as compared to other known processes.
  • the formation of a paste with a high metal concentration is advantageous as this reduces the amount of water that needs to be removed from the paste prior to or during calcination and decreases cost versus existing technologies.
  • a metal salt/copolymer paste as used herein means a soft, smooth solid or semisolid.
  • the copolymers suitable for use in the present invention are amphiphilic copolymers containing ethylene oxide wherein the ethylene oxide content is between 1 and 90 percent.
  • the percent ethylene oxide is the weight percent of ethylene oxide units in the total weight of the copolymer.
  • the ethylene oxide content is greater than about 5 percent of the copolymer. More preferred are copolymers where the ethylene oxide content is about 8 percent or greater. Most preferred are copolymers where the ethylene oxide content is about 10 percent or greater.
  • the ethylene oxide is less than about 80 percent of the copolymer. More preferred are copolymers where the ethylene oxide content is less than about 75 percent.
  • the copolymers are block copolymers containing ethylene oxide.
  • amphiphilic as used herein means a compound which has a HLB between ⁇ 15 and 15 as calculated per Davis, Proc. Intern. Congr. Surface Activity, Vol. 1 London 1957, p. 426.
  • the procedure assigns numeric values to various groups, for example, hydrophilic groups —SO 4 ⁇ Na + , —COO ⁇ K + , and —COOH are assigned values of +38.7, +21.1 and +2.1 respectively; the hydrophobic groups>CH—, —CH 2 —, and —CH 3 are all assigned a value of ⁇ 0.475.
  • the HLB number is calculated by substituting the group numbers into the following equation:
  • HLB ⁇ (hydrophilic group numbers)+ ⁇ (lipophilic group numbers)+7.
  • the copolymers used in the present process have an HLB of greater than ⁇ 10 and preferably less than 13. More preferred are copolymers having an HLB balance of ⁇ 5 to 10.
  • Hydrophilic compounds as defined by the above HLB show a tendency to be fully miscible with water in all proportions under ambient conditions, or in the case of solid materials, at some elevated temperature slightly above their melting point, (for example, about 60° C. for high molecular weight linear polyethylene oxide polymers). In contrast, lipophilic compounds show a tendency to be totally immiscible with water, even at elevated temperatures.
  • the range of HLB values for copolymers of the present invention represent an intermediate case comprising materials which form liquid two-phase systems upon mixing with water (or for solids, after mild heating) such that at least one of the two phases contains more than trace amounts of the opposing phase.
  • this intermediate class is designated as amphiphilic, in contrast with hydrophilic and lipophilic classes representing, respectively the upper and lower segment of the HLB value range.
  • an HLB>15 represents hydrophilic compounds
  • an HLB of ⁇ 15 to 15 represents amphiphilic compounds
  • an HLB of ⁇ 15 represents lipophilic compounds.
  • the copolymers for use in the present invention have an average molecular weight of greater than 400.
  • the copolymers have an average molecular weight of greater than 500. More preferred are copolymers which have an average molecular weight of greater than 750. Most preferred are copolymers which have an average molecular weight of greater than 1000.
  • the average molecular weight of the copolymer is less than about 100,000.
  • the average molecular weight of the copolymer is less than 80,000. More preferred are copolymers with an average molecular weight of less than 50,000.
  • Ethylene oxide copolymers having the percent ethylene oxide content and average molecular weight as described herein can be produced by standard procedures in the art for producing ethylene oxide copolymers.
  • metal refers to metallic or metalloid elements as defined in the Periodic Table of Elements selected from Groups 2a, 3a, 4a, 5a, 6a; 2b, 3b, 4b, 5b, 6b, 7b, 8, 1b and 2b; the lanthanide elements; and the actinide elements.
  • the metal can in principle be of any element from which it is desired to obtain a powder, however those presently having greatest industrial value and suitable for use in the present invention include lanthanum, barium, strontium, chromium, zirconium, yttrium, aluminum, lithium, iron, antimony, bismuth, lead, calcium, magnesium, copper, boron, cadmium, cesium, cerium dysprosium, erbium, europium, gold, hafnium, holmium, lutetium, mercury, molybdenum, niobium, osmium, palladium, platinum, praseodymium, rhenium, rhodium, rubidium, ruthenium, samarium, scandium, sodium, tantalum, thorium, thulium, tin, zinc, nickel, titanium, tungsten, uranium, vanadium, ytterbium, manganese, cobalt, gadolinium or a
  • the metals used can vary based on the application.
  • the metals Bi, Ba, Cu, La, Mg, Nb, Sn, Ti, Zr or a mixture thereof are preferred.
  • Al, Ce, La, Mg, Nb, Y, Zr or a mixture thereof are preferred.
  • the metals are generally used in the form of a salt which is dissolved in a solvent system such as water, alcohol, acetone, tetrahydrofuran, dimethylformamide or other solvent system selected according to its ability to dissolve the metal salts and for its compatibility with the copolymer.
  • a solvent system such as water, alcohol, acetone, tetrahydrofuran, dimethylformamide or other solvent system selected according to its ability to dissolve the metal salts and for its compatibility with the copolymer.
  • the solvent is water.
  • concentration of metal salt present in the solvent is as high as practically possible in consideration of its solubility limit. Where possible it is preferred to use aqueous compositions which are essentially saturated solutions at ambient temperature.
  • the activity of the salt solution will depend on the solubility of the metal salt and the ratio of molecular weight of the metal or metal based compound to molecular weight of the metal salt.
  • the metal solution generally has an activity of greater than 5 percent. Preferably, such solutions have an activity of 7 percent or greater. More preferred are solutions with an activity of 10 percent or greater. Most preferred are solutions with an activity of 15 percent or greater. Generally, the metal salt solution of commercial interest has an activity of less than 50 percent.
  • the amount of copolymer added to the metal salt is generally an amount which does not decrease the activity of the starting salt solution by more than 50 percent (grams oxide obtained after calcination from a metal salt solution compared to the grams oxide obtained after calcination from a metal salt/copolymer mixture).
  • the amount of copolymer added to the metal salt results in less than a 45 percent decrease in activity. More preferably, the amount of copolymer added to the metal salt results in less than 40 percent decrease in activity.
  • Most preferred is a metal salt to polymer ratio such that the decrease in activity is 30 percent or less.
  • a coagulating agent can be added to the metal salt/amphiphilic copolymer.
  • Such coagulating agents are disclosed in WO 99/03629 published Jan. 28, 1999.
  • the coagulating agent is any substance which is able to induce coagulation, that is, induce a change from a fluid state to a solid or semi-solid state, that is, paste.
  • a coagulating agent plus copolymer will increase the surface area of the nanoscale particles over that observed with the copolymer alone, for example, titanium and zirconium.
  • the addition of a coagulating agent will decrease the surface area of the nanoscale particles when compared to the use of a copolymer alone.
  • a determination of whether the coagulating agent will enhance the surface area over that obtained with the use of a copolymer alone can be determined based upon the teachings herein.
  • the coagulating agent can be an organic or inorganic substance.
  • the substance should not leave any residue after pyrolysis/calcining.
  • suitable are primary- or secondary-, amines, amides or alkanolamines. Particularly suitable are, for example, monoethanolamine, diethanolamine.
  • suitable basic substances include for example, ammonium hydroxide, ammonium hydrogen carbonate, ammonium carbonate.
  • inorganic, acidic, coagulating agents include hydrogen sulfide.
  • organic coagulating agents include citric acid, ethylene diaminetetraacetic acid and other carboxylic compounds.
  • the coagulating agent is a hydroxide such as an ammonium solution or an alkaline hydroxide solution, such as sodium or potassium.
  • Ammonium hydroxide is preferred due to its high basicity, attractive water solubility leading to a rapid coagulation result, and absence of an additional metal. Ammonium hydroxide will also be volatilized upon heating.
  • Ammonium hydroxide may be introduced as an aqueous solution, bubbling of NH 4 gas, or alternatively generated in situ by use of a precursor. Examples of precursors include ammonia gas and urea. Urea on exposure to thermal energy undergoes decomposition leading to generation of nascent ammonia, which in the aqueous environment provides for immediate formation of ammonium hydroxide. Formation of ammonium hydroxide by way of urea, provides for an extremely effective distribution of the coagulating agent through-out the composition and in any instances superior to that which can be achieved by direct introduction and mechanical mixing.
  • the amount of coagulating agent to add is preferably at least the amount required to coagulate out the metal under consideration.
  • a process of the present invention results in metal-based powders which have an increase in surface area over powders produced in the absence of the copolymer.
  • the increase in surface area is greater than 30 percent.
  • the amount of copolymer added to the metal salt gives a powder having a greater than 50 percent increase in the surface area. More preferably the copolymer to metal salt is selected to give a powder with a 75 percent increase in the surface area.
  • any equipment commonly used in blending viscous liquids can be employed to produce the composition of this invention.
  • Such equipment provides for the efficient mixing, under high shear conditions, of controlled amounts of aqueous base solution with the aqueous composition comprising both the metal salt and the copolymeric composition. It is presently believed that high shear during mixing is desired so that a fine dispersion of the salt in the paste is obtained. In contrast, it is believed that low shear rates during mixing provide an undesired opportunity for growth of metal salt crystals during the process.
  • the disclosed composition when calcined under controlled conditions, providing for the removal of all organic substance, results in the formation of a substantially uniformly sized, metal-containing powder.
  • the calcining conditions require exposing the composition to a temperature of from 300° C. to 3000° C., and preferably from 400° C. to 1000° C. for a period of a few minutes to many hours.
  • the formed metal salt/copolymer paste can be dried prior to calcination. Drying of the formed paste prior to calcination can increase the surface area of the nanoscale particles, particularly when a coagulating agent is used.
  • the described metal-containing powders having a nanoscale size are of value in the manufacture of ceramic articles, industrial catalysts, electronic components, and as fillers for plastics, paints or cosmetics.
  • the metal-containing powder When used as filler the metal-containing powder will be present, based on the total weight of bulk matrix and powder, typically in an amount of from 0.1 to 50, and more usually in an amount of from 1 to 25 weight percent.
  • the bulk matrix may be for example, a plastic, including a thermoset or thermoplastic polymer, a paint, or a cosmetic composition, cream or oil.
  • the nanoscale particles can also be used in chemical-mechanical polishing as disclosed in U.S. Pat. No. 4,057,939.
  • the composition prior to calcining may be first deposited on at least a portion of a surface of a catalyst support suitable for exhaust emission control (for example, metal, ceramic or combinations thereof).
  • a catalyst support suitable for exhaust emission control for example, metal, ceramic or combinations thereof.
  • the catalyst substrate is a ceramic selected from cordierite, mullite and combinations thereof. More preferably, the substrate is cordierite, acicular mullite or combinations thereof.
  • cerium nitrate (Ce(NO 3 ) 3 .6H 2 O) solutions were prepared by adding 0.5, 1, 2, and 3 kg of cerium nitrate to a liter of water. This represents a calculated activity of 13.2, 19.8, 26.4 and 29.7 respectively.
  • To 80 parts of the various salts solutions was added 20 parts by weight of a copolymer as listed in Table I which gives the initiator name and formula, molecular weight, percent ethylene oxide, propylene oxide and/or butylene content and HLB of the copolymers.
  • Copolymers A-I are examples of the present invention and copolymers J-Q are shown for comparative purposes.
  • the surface area of particles obtained without the addition of any polymer was 54, 62, 65 and 65 m 2 /g of starting solutions of 0.5, 1, 2 and 3 kg metal salt plus 1 liter water (labeled I, II, III and IV in Table II) respectively.
  • the results show a substantial increase in the surface area of nanoscale particles produced using amphiphilic copolymers as compared to the absence of a copolymer or as compared to the use of a hydrophilic or lipophilic copolymer.
  • a 27 percent active solution of titanium chloride in water was made by slowly blending 64.4 parts of TiCl 4 with 35.6 parts of water (by weight).
  • the obtained pastes were calcined at 500° C. for two hours.
  • the surface area and activity of the formed metal powders with and without the addition of NH 4 OH as a coagulating agent are given in Table III.
  • the ammonium hydroxide was added after the addition of the copolymer.
  • a mixed metal solution of zirconium and cerium was prepared by mixing 100 is grams of Zirconia Sol obtained from Magnesium Electronic Limited and 18.3 grams of Cerium(III) nitrate.6H 2 O. This mixture of Zr/Ce gives, upon calcination, approximately an 80/20 percent by weight ZrO/CeO 2 .
  • Gels were prepared by mixing, under vigorous stirring, different amounts of the metal solution, copolymer D, and NH 4 OH as coagulating agent as given in Table IV. Ammonium hydroxide was added after the addition of the copolymer. The obtained gels were calcined at 500° C. for two hours. The surface area and activity of the formed metal powders is given in Table IV.
  • a solution of cerium acetate was prepared by mixing 20 grams of cerium acetate.H 2 O to 100 grams of water. Pastes were prepared by mixing, under vigorous stirring, different amounts of the metal solution, copolymer D, and NH 4 OH as coagulating agent as given in Table V. The ammonium hydroxide was added after the addition of the copolymer. The obtained pastes were calcined at 500° C. for two hours. The surface area and activity of the formed metal powders is given in Table V.
  • Example (m 2 /g) Example Surface area (m 2 /g) 38 125 48 109 39 87 49 108 40 113 50 123 41 105 51 136 42 126 52 114 43 124 53 117 44 110 54 117 45 129 55 125 46 111 56 106 47 91 57 106

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US20050260122A1 (en) * 2004-05-19 2005-11-24 Texas A&M University System Process for preparing nano-sized metal oxide particles
US20060247354A1 (en) * 2004-12-15 2006-11-02 Ping He Method of manufacturing nanoscale metal oxide particles
US20070004840A1 (en) * 2004-05-19 2007-01-04 Texas A&M University Zinc oxide polymer nanocomposites and methods of producing zinc oxide polymer nanocomposites
US20080035025A1 (en) * 2004-04-16 2008-02-14 Tioxoclean Inc. Metal Peroxide Films
US20090029852A1 (en) * 2005-05-02 2009-01-29 Alfred Hagemeyer Molybdenum Compositions And Methods of Making the Same
US20090029167A1 (en) * 2007-07-24 2009-01-29 The Texas A&M University System Polymer nanocomposites including dispersed nanoparticles and inorganic nanoplatelets
US20090199659A1 (en) * 2006-06-20 2009-08-13 Tomonobu Abe Gasket
US20110132144A1 (en) * 2008-07-23 2011-06-09 Jochen Mezger Method For Producing Metal Nanoparticles In Polyols
RU2442751C1 (ru) * 2010-11-08 2012-02-20 Учреждение Российской академии наук Институт проблем химико-энергетических технологий Сибирского отделения РАН (ИПХЭТ СО РАН) Способ получения наноразмерных частиц оксида меди
RU2461668C1 (ru) * 2011-03-16 2012-09-20 Федеральное государственное бюджетное учреждение науки Институт высокотемпературной электрохимии Уральского отделения Российской Академии наук Способ получения наноразмерных частиц сложных оксидов металлов

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Cited By (21)

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Publication number Priority date Publication date Assignee Title
US6753039B2 (en) * 2001-08-03 2004-06-22 Elisha Holding Llc Electrolytic and electroless process for treating metallic surfaces and products formed thereby
US20040217334A1 (en) * 2001-08-03 2004-11-04 Heimann Robert L. Electrolytic and electroless process for treating metallic surfaces and products formed thereby
US20100239862A1 (en) * 2004-04-16 2010-09-23 Pureti, Inc. Process for producing metal peroxide films
US20080035025A1 (en) * 2004-04-16 2008-02-14 Tioxoclean Inc. Metal Peroxide Films
US20100239774A1 (en) * 2004-04-16 2010-09-23 Pureti, Inc. Process for producing metal peroxide films
US8038970B2 (en) 2004-04-16 2011-10-18 Pureti, Inc. Process for producing metal peroxide films
US7727500B2 (en) * 2004-04-16 2010-06-01 Pureti, Inc. Process for producing metal peroxide films
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US7482382B2 (en) 2004-05-19 2009-01-27 The Texas A&M University System Process for preparing nano-sized metal oxide particles
US20060247354A1 (en) * 2004-12-15 2006-11-02 Ping He Method of manufacturing nanoscale metal oxide particles
US20100113260A1 (en) * 2005-05-02 2010-05-06 Symyx Technologies, Inc. Ruthenium compositions and methods of making the same
US20090187036A1 (en) * 2005-05-02 2009-07-23 Symyx Technologies, Inc. Nickel Compositions And Methods of Making the Same
US20090029852A1 (en) * 2005-05-02 2009-01-29 Alfred Hagemeyer Molybdenum Compositions And Methods of Making the Same
US20090199659A1 (en) * 2006-06-20 2009-08-13 Tomonobu Abe Gasket
US8598868B2 (en) * 2006-06-20 2013-12-03 Taiyo Nippon Sanso Corporation Gasket for sealing valve or pipe, determination method of deterioration and damages of gasket, and high-pressure gas supplying equipment
US20090029167A1 (en) * 2007-07-24 2009-01-29 The Texas A&M University System Polymer nanocomposites including dispersed nanoparticles and inorganic nanoplatelets
US8344054B2 (en) 2007-07-24 2013-01-01 The Texas A & M University System Polymer nanocomposites including dispersed nanoparticles and inorganic nanoplatelets
US20110132144A1 (en) * 2008-07-23 2011-06-09 Jochen Mezger Method For Producing Metal Nanoparticles In Polyols
RU2442751C1 (ru) * 2010-11-08 2012-02-20 Учреждение Российской академии наук Институт проблем химико-энергетических технологий Сибирского отделения РАН (ИПХЭТ СО РАН) Способ получения наноразмерных частиц оксида меди
RU2461668C1 (ru) * 2011-03-16 2012-09-20 Федеральное государственное бюджетное учреждение науки Институт высокотемпературной электрохимии Уральского отделения Российской Академии наук Способ получения наноразмерных частиц сложных оксидов металлов

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EP1112223B1 (en) 2003-05-14
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DE69907931D1 (de) 2003-06-18

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